Method of Constructing a Member Suitable for  Traversing Snow

ABSTRACT

Though the sport of snowboarding is not new, it has taken many years to understand the specific characteristics which are required for making snowboards. There is better understanding of the dynamic bending properties needed for current riders, especially for the competition driven rider whose demands are ever changing, driving research and development to new levels on a daily basis. The early designs of snowboards were based on principals learned from the ski industry. Early snowboard designers did not understand or anticipate the use of snowboards as articles for gliding down a snow covered slope making long curving turns and at the same time, the boards to be jumped into the air, launching from half pipes edges and sliding down steel rails. Some of the differences from skis to snowboards can be seen in the prior art for skis. Skis are made for quick turns with a desire to stay firmly attached to the snow surface, where snowboards are made for long carving turns and jumping. Skis are stiff members with a resistance to bending moments and elongation, where these properties are desirable for snowboards. Snowboards are soft and flexible for slow speeds and ski are stiff for high speeds.

PRIOR APPLICATIONS

This application is a divisional application from the originally filed application Ser. No. 11/163,440, which is currently pending, and herein incorporates the aforementioned application filed on Oct. 19, 2005 in the name of Steven Inge, said application being hereby incorporated by reference as if fully set forth herein.

BACKGROUND OF INVENTION

This invention relates to the field of devices that are used to enable the user to slide or glide across surfaces such as snow and ice. The device that is particular suited for this invention is a snowboard. As one skilled in the art will recognize, an application of this invention can extend further than just to the field of snowboarding, and as such would be covered by the concept and spirit of this invention.

DESCRIPTION OF THE ART

This invention accomplishes some of the attributes desirable for a user to have a device that contains both damping characteristics and a cantilever stiffening aspect in one device. It is desirable for those who participate in the activity of snowboarding to have a board that is soft or damping around the edges, which will keep the snowboard conforming to the terrain, while at the same time being able to have the snowboard “spring” back to it's natural state after being bent around moguls, contours or steel pipe rails. Snowboarding is different from skiing as there is more demand for freestyle jumping and riding on the edge of object. Skiing demands more bending of the ski with extreme flexural characterstics, as skiers tend to ride moguls, contours and uneven terrain, seeking the ski to smoothly transition between valleys and peaks. Snowboarding on the other extreme has more jumps and skateboarding types of terrian where the snowboard needs to “grab” the surface, damping, but also need to provide “spring” or lift when jumping from the edge of half-pipes and rails. Also a snowboard is more likely to be subjected to flexural and compressive forces in one direction at the same time and than the opposite forces will be subjected on the board in the next immediate moments. Snowboards need to adapt to bending moments in both the vertical and horizontal planes which are constantly and rapidly changing.

The prior art for those devices which can be used for gliding across snow can generally be described as layering materials of various properties longitudinally along the vertical axis of the device. U.S. Pat. No. 4,412,687 issued to Andre on Nov. 1, 1983 discloses a ski that is laminated with high tensile strength materials, rods and filament bundles. The goal is to increase the rigidity and bending strength of the ski. U.S. Pat. No. 4,706,985 issued to Meatto on Nov. 17, 1987 also discloses the basic concept of layering materials to obtain the desired characteristic of the device. Meatto combines both circular rods and sheets of various components to increase flexural response and compressive structural strength of the ski. Snowboard though need to be soft and flexible not stiff as skis. The early snowboards were built as having the same composition of skis. But as snowboarding developed into a different style of sport from skiing, the design of snowboards have started to develop to adapt to this change in use. The prior art of snowboard design has followed the designs of both skis and skateboards.

Snowboards have three distinct sections, the main body, the front tip or nose, and the rear tail. Each is shaped different and in snowboards the tip and tail are significantly larger in width than is the body. Snowboards are riding with the center of gravity of the user generally over the center of gravity of the snowboard, where in skis the center of gravity is shifted toward the tail of the ski. The skier faces the along the axis of motion, where the snowboarder is transverse to the axis of motion, needing a wider plane in order to attach themselves to the snowboard and creating the need for torsional movement rather than axial movement, Generally, this torsional movement is generated on the edge of the snowboard and thus snowboards are now built with this recognition of movement in mind. Prior art shows snowboards developing softer edge material so that the snowboard is easier to carve in long turns. Patent Publication 2002/0105165 for DeRocco published Aug. 8, 2002 details this concept of varying edge properties by using ABS or other relatively rigid materials in different shapes and thicknesses in the core of the board disclosing that some rider like a stiffer board. U.S. Pat. No. 6,499,758 issued to Fournier on Dec. 31, 2002, discloses a complex series of angles and grooves designed to reduce the compression forces necessary to bend the board. U.S. Pat. No. 6,382,658 issued to Stubblefield on May 7, 2002 discloses a plurity of cross-sections and thicknesses of core to create an improved turning performance. These are both very complex to design and difficult to manufacture and thus they become very expensive and custom to a particular need of a rider in a particular situation, long smooth turns of Fournier to the sharp tight turns of Stubblefield. It would be desirable for a snowboard to be able to adapt to a multitude of different situations as they present themselves while snowboarding down a mountain slope. U.S. Pat. Nos. 6,520,530 and 6,105,991 issued to Dodge et al on Feb. 18, 2003 and Aug. 22, 2000 respectively, addresses the issue of having various directions of the strength of materials so that the material's direction of strength is located along the areas of greatest stress on the snowboard. This is very complex and arduous task of aligning materials for a particular style of riding. These claim vertically laminated members which are non-parallel to the core axis and anisotropic structures oriented so that the principal axis is not in alignment with any of the core axis. It would be desirable to produce a snowboard that is can be readily manufactured that would contain the attributes of the prior art. It would be advantageous to be able to have a snowboard that combines the riders desires as well as the conditions available for him to ride. It would be desirable to have snowboard that is customizable in a short amount of time and can be mass produced for varying levels of ability uses the same concepts and materials

This invention derives it's uniqueness from a combination of responsive materials and a cantilever inspired spring return system. The main uniqueness of this invention is that it treats the core and tail and tip as third separate entities which enable the invention to focus on the different materials necessary for each part of the board to function as a unit yet have the different characteristics in the unique areas of the snow board. The choice of materials is developed about the nature of the conditions during use and construction of the snowboard. Materials must have consistent properties through-out the cold regions where the board is made, yet do not have their properties depreciated during the pressure, bending and heating process during construction. Where flex is required in the tail and tip, softer material is used, where the core of the body is stiff for responsiveness, and yet the edges are softer. The use of carbon fiber stiffening member “spring” the snowboard back to it's natural state quickly, so that the snowboard is ready to absorb the next grueling round of stresses around the next corner or half-pipe jump. This invention can be customizable by adjusting the stiffness of the snowboard by adding or subtracting stiffening members or by adjusting the thickness of the stiffening member.

DESCRIPTION OF FIGURES

The following figures are included to graphically detail the invention.

In FIG. 1, the interior core, tail and tip of the snowboard is shown.

In FIG. 2, a profile of the snowboard is taken directly down the vertical centerline or section B-B as shown in FIG. 1. The entire snowboard is shown with the top and bottom layers along with the core.

In FIG. 3, the snowboard is shown on a horizontal profile, cut along section A-A. In this figure, the snowboard is shown with only 1 stiffening member on each side of the core.

In FIG. 4, the snowboard is shown on a horizontal profile, cut along section A-A. In this figure, the snowboard is shown with 2 stiffening members on each side of the core, located equidistant from the vertical center of the board.

In FIG. 5, the detail of the stiffening member and associated channel is shown in profile view.

In FIG. 6, is a layered view of the snowboard, where each layer is shown by hatch pattern along with the stiffening member. Detail of the dovetail joint is also seen with this figure.

DETAILED DESCRIPTION OF THE INVENTION

In FIG. 1, the body 2 of the snowboard 1 is shown. Body 2 comprises tip 3, tail 4, core 5, at least 2 stiffening members 6, with an equal number of channel 7 corresponding to stiffening members 6, and perimeter edge 8. Core 5 is defined by right vertical plane wall 9 and left vertical plane wall 10 and upper horizontal plane wall 11 and lower horizontal plane wall 12. Core 5 is also defined by a front side of core 17 and a rear side of core 18 which extends in the horizontal plane between right vertical plane wall 9 and left vertical plane wall 10. Surface of front side 17 and rear side 18 is generally without surface defects. Central riding surface 40 is defined as that area between the riders feet as they are attached via mountings to the board 1 extending from right vertical plane walls 9 through the vertical axis B-B to left vertical plane wall 10. Riding surface 40 is characterized as having an equal distance between front side 17 and rear side 18 at corresponding points. Said vertical plane walls 9 and 10 are equal in length and are terminated by right edge 13 and left edge 14, where right edge 13 and left edge 14 form right angle vertexes upon joining with vertical plane walls 9 and 10. Right edge 13 and left edge 14 are circumscribed about an arc of a circle whose radii depends upon personal users preferences. Generally, a radius of approximately 1000 cm is used. Core 5 has a vertical axis of core B-B which is described as being the latitudinal line which is equidistant from corresponding points in the horizontal plane along said right edge 13 and said left edge 14. Vertical axis of core B-B is along the vertical axis of rotation. Core 5 has a horizontal axis of core A-A which a latitudinal line described as intersecting said vertical axis of core B-B at a right angle and is equidistant from corresponding points on upper horizontal plane wall 11 and lower horizontal plane wall 12. Midpoint 31 is defined as the intersection of vertical core axis B-B and horizontal core axis A-A. Front side of core 17 is has a reduction in thickness contour 32 tapered commencing at the distal of mounting holes 39, tapering toward horizontal plane walls 11 and 12. The reduction of thickness along contour 32 extends at a constant rate creating an equal thickness of the core extending from right vertical plane wall 9 to left vertical plane wall 10. Core 5 has a thickness at midpoint 31 of between 4-10 mm, preferable 6-8 mm. Core 5 has a thickness of between 1-6 mm at horizontal plane walls 11 and 12, preferably 2-4 mm. In this invention, core 5 follows contour 32 from 6 mm to 3 mm in thickness. Contour 32 can have a slope that contains a radius or has a straight slope toward it termination point at the horizontal walls. Tip 3 and tail 4 are joined with equal thickness to horizontal plane wall 11 and 12. Upper horizontal plane wall 11 and lower horizontal plane wall 12 are adapted for maximum bonding adhesion by increasing the surface area of the bond between core 5 and tip 3 and core 5 and tail 4. In this invention, a dovetail design 20 is used to accomplish this goal of maximum adhesion. This invention is not limited to a particular design. The goal is to create the maximum necessary bond between said core 5 and tip 3 and core 5 and tail 4. Bonding means are used to enhance dovetail 20 adhesion to tip 3 and tail 4. The distance between said front side of core 17 and rear side of core 18 at any one point of core 5 is predetermined by the style of use of said board 1. This invention is not limited to specific contour angle or lack thereof. Binding mounting holes 19 are located along vertical axis of core B-B, corresponding to predetermined inserts necessary for mounting bindings to said board 1 after completion of bonding of the layers. Binding mounting holes 19 are threaded inserts whose exterior is adapted for maximum adhesion during the bonding process in this invention. Mounting holes 19 are adapted by location to fit the particular design of bindings to be used on board 1. Core 5 can be made from wood, such as birch, aspen, balsa or other lightweight woods or polymer based materials.

Right edge 13 and left edge 14 has circumscribed thereabout a perimeter edge 8. Perimeter 8 is equivalent in height as is the height of edge 13 and 14 and is bonded to edge 13 and 14 using bonding means. Perimeter edge 8 follows the radius of vertical plane walls 9 and 10. Perimeter edge 8 extends in the horizontal plane a pre-determined distance based on desired board characteristics. Perimeter edge 8 is made of a isotropic material which is invariant with respect to any direction. This material must has stability of characteristics throughout the range of temperatures for where board 1 is to be subjected thereto and also not have any degradation of material characteristics when subjected to bonding means. In this invention, Celluarized or Expanded polyvinylchloride is used with of density of between 0.35 and 1 g/cm³, preferably 0.55 to 0.75 g/cm³. Perimeter 8 edge extends beyond upper horizontal plane wall 11 following tip cutin radius 41, terminating at the transition between the radii of vertical plane walls 9 and 10 and the tip radius 43. Perimeter 8 edge extends beyond lower horizontal plane wall 12 following tail cutin radius 42, terminating at the transition between the radii of vertical plane walls 9 and 10 and the tail radius 44.

Tail 4 is defined by a distance from the lower horizontal plane wall 12 to the apex of tail radius 38. Tail 4 constructed of material similar in characteristics to perimeter edge 8 and is connected to tail cutin radius 42 using bonding means. Tail radius 44 is defined as the curvature needed to connect the termination of vertical plane wall 9 and 10 to apex 38. Distance from lower horizontal plane wall 12 to apex 38 is determined by the characteristics of board 1 by the riders. In this invention, the distance is approximately 20-24 cm. Tail 4 contains at least one tail extension channel 37 which similar in shape dimensions as channel 7 and constitutes a continuation of channel 7 from core 5 to tail 4. There will exist at least an equal number of tail extension channel 37 corresponding to top channel 33 and bottom channel 34 that exist on core 5. Tail extension channel 37 will vary in length depending upon the particular characteristics required of board 1. Tail extension channel 37 will vary from 50% to 90% of the distance from lower horizontal plane wall 12 to apex 38.

Tip 3 is defined by a distance from the upper horizontal plane wall 11 to the apex of tail radius 36. Tip 3 constructed of material similar in characteristics to perimeter edge 8 and is connected to tail cutin radius 41 using bonding means. Tail radius 43 is defined as the curvature needed to connect the termination of vertical plane wall 9 and 10 to apex 36. Distance from upper horizontal plane wall 11 to apex 36 is determined by the characteristics of board 1 by the riders. In this invention, the distance is approximately 26-30 cm. Tip 3 contains at least one tip extension channel 35 which similar in shape dimensions as channel 7 on core 5 and constitutes a continuation of channel 7 from core 5 to tip 3. There will exist at least an equal number of tip extension channel 35 corresponding to top channel 33 and bottom channel 34 that exist on core 5. Tip extension channel 35 will vary in length depending upon the particular characteristics required of board 1. Tip extension channel 35 will vary from 50% to 90% of the distance from upper horizontal plane wall 11 to apex 36.

FIG. 5 details the channel and stiffening members. There are at least two channel 7 each having the depth equivalent to the thickness of stiffening member 6. Channel 7 is defined by channel sides 21 and channel bottom 22. Stiffening member 6 is placed directly onto channel bottom 22 and in proximal contact with channel sides 21. Bonding means is used to secure stiffening member 6 to channel sides 21. Channel 7 is milled or routed into the surface of core 5 as shown in FIG. 3 and 4. FIG. 3 describes a top side channel 33 which contains two channel sides 21 that are perpendicular to front side of core 17 and a lower side channel 34 also contains two channel sides 21 that are perpendicular to rear side of core 18. In this embodiment of the invention that is detailed in FIG. 3, there is one top side channel 33 and one lower side channel 34, the horizontal center of each channel being located along the vertical axis of core B-B. The length of channel side 21 can be equal for top side channel 33 and lower side channel 34 or the length channel side 21 may be different between top side channel 33 and lower side channel 34, should the rider want to have a different rebound response between the flexation and compression of the stiffening members in the channels. For example, a rider who wishes to have board 1 that has a soft feel for trick riding, might wish to have a board that will bend more easily from the top of the board, but would wish for a stiffer bottom of the board to return or spring the board back to it's natural position. It is the characteristic of this invention to always have an equal number of said channel 7 inlaid on said front of core 17 and as there is inlaid on said rear of core 18. FIG. 4 shows the addition of one top side channel 33 and one lower side channel 34 for a total of 2 on each side. In this embodiment of the invention, each front side channel is symmetrically placed about the vertical axis of core B-B. Each lower side channel is symmetrically placed about the vertical axis of core B-B directly opposite of the front side channel. It is the theory of this invention that the opposing forces supplied by the opposing stiffening members, one being in tension while the other is in compression, is what gives this invention the desired characteristics. This does not preclude the adaptation of variations in placement of the stiffening members in relation to one another, as that would be within the spirit of this invention. In this embodiment, said channel 7 in inlaid through the entire vertical distance of core 5 extending beyond said upper horizontal plane wall 11 and lower horizontal plane wall 12. It is within the spirit of this invention to reduce to length of said channel 7 to lengths less than that of the vertical distance of said core 5.

Core 5, in combination with bondly attached tip 3, tail 4 and perimeter edge 8 and along with bondly attached stiffening members 6, constitutes body 2. Body 2 is laminated to bottom layer 45 using bonding means. Bottom layer 45 is defined by upper bottom layer 49 and lower bottom layer 48 and bottom layer edge 50. Circumscribed about bottom layer edge 50 is metal carving extension rail 46 which is bondly attached to edge 50 using bonding means. Rail 46 is a flexible metallic piece that when sharpened after installation creates a edge that is able to carve into the solid ice facilitating turning of board 1 in icy conditions. The interface between edge 50 and rail 46 differs in shape corresponding to the type of rail 46 used. In this invention, FIG. 3 and 4 describe a rail 46 which has an inclined angle, increasing the bonding surface area, which dictates the corresponding angle of edge 50. Bottom layer edge 50 with the bonded rail 46 proscribes a profile in the horizontal plane that conforms to the profile of body 2. Upper bottom layer 49, along with rail 46 is covered with bonding strengthening material 47 and bonding means. Body 2 is placed on top of upper bottom layer and accompanying bonding materials.

Top layer 51 is profiled to match body 2. Top Layer 51 is modified to accept mounting holes 19. Body 2 is layered with bonding strengthening material 47 and bonding means and then top layer 51. Board 1 is then subjected to pressure and heat to cure the bonding material and to shape the vertical profile of the board as shown in FIG. 2. After cure, vertical edge angle 52 is produced. Grinding means are used to shape a 45 degree angle emanating from the upper outer corner 53 of rail 46, shaping the 45 degree angle in toward midpoint 31 along the entire outside surface of the rail 46. After processing the angle 52, board 1 is ready for final preparations for use. Bottom side of bottom layer 48 is roughed up using low grit sandpaper or similar device so that it is adapted to receive a waxing compound which decreases friction between the board 1 and the snow. Upper layer of top layer 51 has applied thereupon multiple layers of liquid substances, such as acrylics, that will enhance the visual attributes of board 1 and will increase the surface hardness to prevent damage to the top layer of board 1.

Bonding means used in the construction of board 1 incorporate those characteristics which will provide superior adhesion of unlike materials, can be strengthened using bi-directional or omni-directional reinforcing materials, such as glass, carbon, metallic or similar natural or manmade fibers and can withstand temperature deviations typical where board 1 will be manufactured and used. In this invention, epoxy 53 is used as the bonding agent along with glass fiber mesh material, described as bonding strengthening material 47. The bonding material is subjected to heats up to 80 degrees Celsius and pressures up to 80 pounds per square inch during the curing process. The curing process is done in a press where the concave and convex shapes of the board are produced using opposing dies.

It is obvious that one that is skilled in the art will be able to adapt this invention's method to create items other than snowboards. Anyone who has an application whereby panel members that have requirements of varying bending moments and stiffness requirements can use this method to create such panels where extreme end sections of such panels can have a different composition than the main body of the panel. 

1. A Method of constructing a sliding device for traversing snow comprising the steps of; Shaping a core, a tail and a tip to corresponding radii; Creating holes for inserts and inserting said inserts into core for binding mountings; Contouring plateaus in said core in vertical plane to desired thickness; Making dovetail joint on mating surfaces; Conforming perimeter edge material to outside edges of core; Feathering perimeter edge material on core to intersection of core radius and nose radius along core radius; Feathering perimeter edge material on core to intersection of core radius and tail radius along core radius; Inlaying channels onto exterior surfaces of core, tip and tail; Assembling tip and tail onto core and perimeter edge creating core assembly; Placing stiffening members into channels and bonding said members to said channel; Shaping a bottom layer to match shape of said core assembly; Conforming metal carving extension rail to entire perimeter of said bottom layer; Conforming a top layer to match shape of said core assembly; Creating holes in said top layer matching said inserts in said core; Bonding said bottom layer and said top layer to said core assembly using glass omni-directional glass fiber mesh material to stabilize bonding material and bonding pieces; Placing assembled device into shaping press; Supplying heat and pressure to press; Holding pressure and heat for period of time; Releasing shaped assembled device from press; Preparing said top layer for surface enhancements; and Preparing said bottom layer for accepting waxing materials.
 2. A Method of constructing a sliding device for traversing snow as in claim 1 where the bonding material used is epoxy.
 3. A Method of constructing a sliding device for traversing snow as in claim 1 number of channels are the same on each exterior surface of core, tip and tail.
 4. A Method of constructing a sliding device for traversing snow as in claim 1 number of channels are not the same on each exterior surface of core, tip and tail.
 5. A Method of constructing a sliding device for traversing snow as in claim 1 thickness of the stiffening members are the same on each exterior surface of core, tip and tail.
 6. A Method of constructing a sliding device for traversing snow as in claim 1 thickness of the stiffening members are not the same on each exterior surface of core, tip and tail.
 7. A Method of constructing a sliding device for traversing snow as in claim 1 where the material used on the perimeter edge, tip and tail is an isotropic material with of density of between 0.35 and 1 g/cm³, preferably 0.55 to 0.75 g/cm³.
 8. A Method of constructing a sliding device for traversing snow as in claim 1 where said front stiffening member and said rear stiffening member are constructed of polymer based material that contains a unbiased carbon based rigidity enhancements, wherein said unbiased carbon based rigidity enhancements is a material selected from the group consisting of uni-directional, bi-directional and omni-directional fibers.
 9. A Method of constructing a sliding device for traversing snow as in claim 1 where said bottom layer is constructed of a polymer such as ultra high molecular weight polyethylene.
 10. A Method of constructing a sliding device for traversing snow as in claim 1 where said top layer is constructed of a colored UV-stabilized polymer selected from the group consisting of polybutylene terephthalate, acrylonitrile-butadiene-styrene copolymers, and ultra high molecular weight polyethylene.
 11. A Method of constructing a sliding device for traversing snow as in claim 1 where said core is made of a wood. 